DUCATI 1098/1098S Service Manual

A B C D E F G H L M N P Draft copy 0 General 0 Information about the model 0 Technical data 0 Use and maintenance 0 Fairings 0 Controls - Devices 0 Wheels - Suspension - Brakes 0 Frame 0 Fuel / Exhaust System 0 Injection - ignition system 0 Engine 0 Electric system 0 GENERAL SUMMARY 0

A B C D E F G H L M N P 2 1098/1098S - M.Y. 2007 - edition 00 General summary Section A General 0 1 - How to use this manual 3 Layout of the manual 4 2 - Symbols - Abbreviations - References 5 Product specifications 6 3 - Hazardous Products - Warnings 8 General safety rules 8 General maintenance indications 10 Section B Information about the model 0 1 - Identification data 3 Identification data for the Superbike 1098 3 Section C Technical data 0 1.1 - Technical specifications 3 General 3 Colours 4 Transmission 4 Timing system/valves 5 Crankshaft 5 Cylinder/Piston 5 Gearbox 6 Cooling system 6 Front wheel 6 Front suspension (1098) 6 Front suspension (1098S) 7 Rear wheel 7 Rear suspension (1098) 7 Rear suspension (1098S) 7 Hydraulic brakes 8 Charging system/alternator 8 Injection - ignition system 8 Fuel system 8 Lights/instrument panel 9 1.2 - Dimensions 10 2 - Fuel, lubricants and other fluids 11 3 - Torque settings 12 Frame torque settings 12 Engine torque settings 13

A B C D E F G H L M N P 3 1098/1098S - M.Y. 2007 - edition 00 General summary 4 - Service tools 16 Special tools for the engine 16 Special tools for the frame 22 Section D Use and maintenance 0 1 - Preliminary checks 3 Running-in precautions 3 Pre-ride checks 4 2 - Starting - Engine warmup 5 Starting the engine 5 3 - Routine maintenance table 6 Programmed maintenance plan: operations to be carried out by the dealer 6 Programmed maintenance plan: operations to be carried out by the dealer 8 4 - Maintenance operations 9 Checking the engine oil level 9 Changing the engine oil and filter cartridge 10 Checking valve clearances 13 Adjusting the valve clearances 14 Checking the coolant level 15 Change the coolant 16 Changing and cleaning the air filters 17 Changing the brake fluid 19 Draining the braking circuit 22 Fill the brake system with fluid 24 Changing the clutch fluid 27 Draining the clutch hydraulic circuit 28 Filling the clutch circuit 30 Adjusting the steering head bearings 32 Adjusting the chain tension 33 Checking brake pad wear and changing brake pads 35 Adjusting the throttle cable 38 Adjusting the clutch lever and front brake lever 40 Adjusting the position of the gearchange and rear brake pedals 41 Adjusting the front fork 42 Adjusting the rear shock absorber 43 Adjusting the rear ride height 45 5 - Diagnostic instruments 47 Description of the Ducati Diagnostic System instrument 48 Tester power supply 50 DDS tester 53 Checking and adjusting timing belt tension 54 Resetting the throttle position sensor (TPS) 58 Adjusting the idle speed 62 Checking the engine oil pressure 66 Cylinder compression test 71 Fuel pressure test 74 Immobilizer override procedure 77 Guided diagnosis 81

A B C D E F G H L M N P 4 1098/1098S - M.Y. 2007 - edition 00 General summary Testing the battery charging system 84 Deactivating the “maintenance” indication on the instrument panel 87 Icons table 90 Section E Fairings 0 1 - Headlight shell - rear-view mirrors 3 Removal of the rear-view mirrors 4 Refitting the rear-view mirrors 5 Removal of the headlight shell 6 Refitting the headlight shell 8 2 - Fairing panels 11 Removal of the side fairings 12 Removal of the front shield 14 Refitting the front shield 14 Refitting the side fairings 15 3 - Seat - seat cowling and side panels 17 Removal of the seat 18 Removal of the side panels and seat cowling 19 Refitting the side panels and seat cowling 22 Refitting the seats 26 Refitting the pillion seat 27 4 - Front mudguard 28 Removal of the front mudguard 28 Refitting the front mudguard 29 Section F Controls - Devices 0 1 - Throttle and choke controls 3 Adjusting the throttle cable 4 Removal of the throttle cable 4 Refitting the throttle twistgrip 5 2 - Hydraulic clutch control 7 Removal of the clutch master cylinder assembly 8 Refitting the clutch master cylinder assembly 9 Removal of the clutch slave cylinder 11 Refitting the clutch slave cylinder 13 3 - Front brake control 16 Removal of the front brake master cylinder 17 Refitting the front brake master cylinder 18 4 - Rear brake control 19 Removal of the complete rear brake control 20 Disassembly of the rear brake master control 21 Refitting the rear brake control 22

A B C D E F G H L M N P 5 1098/1098S - M.Y. 2007 - edition 00 General summary 5 - Gearchange control 23 Removal of the complete gearchange control 24 Disassembly of the gearchange control 25 Refitting the gearchange control 26 Section G Wheels - Suspension - Brakes 0 1 - Front wheel 3 Removal of the front wheel 4 Overhauling the front wheel 6 Refitting the front wheel 9 2 - Front fork (1098) 11 Removal of the front forks 12 Overhauling the front forks 13 Refitting the front forks 20 3 - Hydraulic front brake 22 Maintenance operations 23 Removal of the front brake system 24 Refitting the brake discs 26 Overhauling the front brake components 27 Refitting the front brake system 28 4 - Rear wheel 30 Removal of the rear wheel 31 Overhauling the rear wheel 32 Refitting the rear wheel 33 5 - Rear swingarm 34 Removal of the rear eccentric hub 35 Removal of the rear eccentric hub 37 Removal of the swingarm 39 Inspecting the swingarm pivot shaft 41 Overhauling the rear swingarm 42 Refitting the swingarm 46 6 - Hydraulic rear brake 48 Removal of the rear brake caliper 49 Removal of the rear brake disc 50 Refitting the rear brake caliper 51 7 - Rear suspension 52 Rear suspension system 53 Removal of the rear shock absorber 54 Overhauling the rear shock absorber 55 Removal of the rear suspension rocker arm 56 Overhauling the rear suspension rocker arm 57 Disassembly and overhaul of the shock absorber tie-rod 58 Refitting the rear suspension 59

A B C D E F G H L M N P 6 1098/1098S - M.Y. 2007 - edition 00 General summary 8 - Final drive 61 Inspecting the final drive 62 Removal of the front sprocket 63 Refitting the front sprocket 65 Renewal of the rear sprocket 67 Refitting the rear sprocket 68 Washing the chain 69 Lubricating the chain 69 Section H Frame 0 1 - Handlebars 3 Removal of the handlebars 4 Refitting the handlebars 5 2 - Steering 6 Adjusting the steering head bearings 7 Steering angle adjustment 8 Removal of the steering head components 9 Refitting the steering head components 11 3 - Steering damper (1098) 14 Removal of the steering damper 15 Refitting the steering damper 16 4 - Footrest brackets 17 Removal of the footrests 18 Refitting the footrests 19 5 - Stands 20 Removal of the sidestand. 21 Refitting the sidestand 23 6 - Frame inspection 24 Disassembly of structural components and the frame 25 Checking the frame 29 Reassembly of structural components and the frame 31 7 - Number plate holder 33 Removal of the number plate holder 34 Section L Fuel / Exhaust System 0 2 - Fuel tank 3 Removal of the fuel tank 4 Removal of the fuel filler cap assembly 6 Refitting the fuel filler cap assembly 7 Renewal of the fuel tank flange 8 Refitting the fuel tank flange 9 Refitting the fuel tank 10

A B C D E F G H L M N P 7 1098/1098S - M.Y. 2007 - edition 00 General summary 6 - Airbox - Throttle Body 14 Removal of the throttle body 15 Refitting the airbox and throttle body 23 7 - Air intake 29 Removal of the air filters 30 Refitting the air filters 31 8 - Exhaust system 32 Removal of the exhaust system 33 Refitting the exhaust system 37 Section M Injection - ignition system 0 2 - Fuel injection-ignition system 3 3 - System components 4 Electronic Control Unit (ECU) 4 Removal of the battery support 6 Refitting the battery support 9 Electric injector 14 Air pressure sensor 15 Coolant temperature sensor 16 Air temperature sensor 17 Ignition coils 18 Throttle Position Sensor (TPS) 21 Rpm/timing sensor 22 Injection relay 23 CAN Line 24 Section N Engine 0 1 - Removal–refitting of the engine assembly 5 Removal of the engine 6 Refitting the engine 9 2.1 - Lubrication system: oil pump 10 Removal of the oil pump 11 Disassembly of the oil pump 12 Reassembly of the oil pump 13 Refitting the oil pump 14 2.2 - Lubrication system: oil cooler 15 Removal of the lubrication system 16 Oil cooler inspection 18 Refitting the lubrication system 18

A B C D E F G H L M N P 8 1098/1098S - M.Y. 2007 - edition 00 General summary 3.2 - Cooling system: radiator 20 Removal of the radiator 21 Renewal of the cooling fan 23 Refitting the radiator 24 Removal of the cooling system hoses and unions 26 Refitting the cooling system hoses and unions 29 3.3 - Cooling system: water pump 32 Removal of the water pump 33 Refitting the water pump 36 4.1 - Cylinder head assemblies: checks and adjustments 41 Checking and adjusting the valve clearances 42 Checking valve lift 44 Checking the engine timing 46 4.2 - Cylinder head assemblies: timing 49 Removal of the timing belt covers 50 Removal of the tensioner pulley/timing belt 51 Removal of the camshaft pulleys/idler pulley 51 Removal of the tensioner and idler pulley mounting studs 52 Disassembly of the camshaft pulleys 53 Removal of the timing belt driveshaft pulleys 54 Refitting the timing belt driveshaft pulleys 56 Refitting the idler and tensioner pulley mounting studs 58 Reassembly of the timing pulleys 59 Refitting the camshaft pulley/idler pulley 60 Refitting the timing belts 63 Refitting the timing covers 65 4.4 - Cylinder head assemblies: camshafts 66 Removal of the camshafts 67 Checking the camshafts and supports 69 Refitting the camshafts 70 Removal of the intake manifold and coolant union 76 Refitting the intake manifold and coolant union 77 4.5 - Cylinder head assemblies: valves–rocker arms 78 Removal of the cylinder heads 79 Removal of the valves 80 Removal of the valve rocker arms 81 Overhaul of cylinder head components 84 Reassembly of the cylinder head 91 Fitting the cylinder head assemblies 98 5 - Cylinder/piston assemblies 100 Disassembly of the cylinder/piston 101 Overhaul of the cylinder barrel/piston components 104 Refitting the cylinder/piston assembly 109 6.1 - Clutch assembly: clutch 113 Description 114 Disassembly of the clutch 115 Inspection and overhaul of the clutch components 120 Reassembly of the clutch 122

A B C D E F G H L M N P 9 1098/1098S - M.Y. 2007 - edition 00 General summary 6.2 - Clutch assembly: right-hand side crankcase cover 126 Removal of the right-hand side crankcase cover 127 Disassembly of the right-hand side crankcase cover 128 Reassembly of the right-hand crankcase cover 129 Refitting the right-hand side crankcase cover 131 6.3 - Clutch assembly: primary drive gears 133 Removal of the primary drive gears 134 Refitting the primary drive gears and checking backlash 137 7.1 - Gearbox assembly: gearchange mechanism 140 Removal of the gearchange mechanism 141 Disassembly of gear interlock plunger and pawl assembly 143 Refitting the gear interlock plunger and pawl assembly 144 Refitting the gearchange mechanism 145 7.2 - Gearbox assembly: gearbox shafts 147 Removal of the gearbox assembly 148 Disassembly of the gearbox shafts 150 Overhaul of the gearbox 155 Inspection of the gear selector forks 156 Inspection of the gear selector drum 157 Reassembly of the gearbox shafts 158 Reassembly of the gearbox 162 8 - Flywheel/alternator 163 Removal of the left-hand side crankcase cover 164 Disassembly of the left-hand crankcase cover 166 Removal of the flywheel/alternator assembly 167 Overhaul of the flywheel/alternator assembly 169 Refitting the flywheel/alternator assembly 177 Refitting the left-hand crankcase cover 179 9.1 - Crankcase assembly: external components 182 Removal of external components 183 Refitting the external components 186 Removal of the timing gears 190 Refitting the timing gears 191 Removal of the starter motor idler gear 192 Refitting the starter motor idler gear 193 Checking the engine sensor air gap 194 9.2 - Crankcase assembly: crankcase halves 195 Separation of the crankcase halves 196 Overhaul of the crankcase halves 199 Main bearings 203 Reassembly of the crankcase halves 204 Shimming the shafts 207 Reassembly of the crankcase halves 212 9.3 - Crankcase assembly: connecting rods 218 Removal of the connecting rods assembly 219 Disassembly of the connecting rods 220 Overhaul of the connecting rods 221 Reassembly of the connecting rods 226 Refitting the connecting rods. 228

A B C D E F G H L M N P 10 1098/1098S - M.Y. 2007 - edition 00 General summary Section P Electric system 0 1 - Wiring diagram 4 Key to wiring diagram 5 Wiring colour codes 6 Key to fusebox 6 Routing of wiring on frame 7 Plate 1 9 Plate 2 9 Plate 3 10 Plate 4 10 Plate 5 11 Plate 6 11 Plate 7 12 Plate 8 13 Plate 9 14 Plate 10 14 Plate 11 15 Plate 12 15 Plate 13 16 Plate 14 17 Plate 15 18 Plate 16 19 Plate 17 20 Plate 18 21 Plate 19 22 Plate 20 23 Plate 21 24 Plate 22 24 Plate 23 25 Plate 24 26 Plate 25 27 Plate 26 28 Plate 27 29 Plate 28 30 Plate 28 31 Plate 29 32 Plate 30 33 Plate 31 34 Plate 32 35 Plate 33 36 Plate 34 37 Plate 35 38 2 - Battery charging system 39 Checking the battery charging system 39 Recharging the battery 40 Topping up the electrolyte 41 Battery 44 Alternator 46 Regulator/rectifier 49

DUCATI 1098/1098S Service Manual

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